Macromedia™ Introduces a Revolutionary Solution for Pre-Grinding and Dispersion Needs

Best Product Quality Achieved Using Smallest Possible Bead Size When small beads are used, contact surface area between beads and pigments increases significantly and gaps between beads decrease. This enables more efficient grinding. However, certain barriers exist to using small beads. First, the product viscosity must be suitable for this. The other barrier we will focus on in this article is pre-mix quality. (Figure 1) The influence of pre-mix quality on the bead size we use is based on one of the most fundamental rules of grinding: to prevent filter clogging, the filter opening size must be larger than the largest particle size in the pre-mix. The filter's primary function is to keep beads inside the grinding chamber. The bead size should be at least two times (preferably three times) the filter opening size. In this very general and rough approach, we can say that bead size cannot be less than two times (and/or preferably three times) the particle size in the pre-mix. However, if we can further reduce the particle size in the pre-mix, we can reduce both filter opening and bead size. In Figures 2 and 3, you can see results of some studies we conducted at our application center in Uzwil, Switzerland. As we can see in Figure 2, by using smaller beads we can reach the target particle size with less specific energy or achieve smaller sizes with the same specific energy. This also indicates more efficient and faster production. Figure 3 shows a similar pattern. By using small beads we can reach the desired product quality with less specific energy (shorter production time) or achieve better product quality by applying the same specific energy.

Benefits that small particle size in the pre-mix will provide us can be listed as follows:

• Best particle size distribution – Quality, • Best color strength – Pigment efficiency, • Best gloss and transparency – Value-added product, • Highest throughput – Productivity. [gallery columns="2" size="full" ids="eyJ1cmwiOiJodHRwczpcL1wvd3d3LnR1cmtjaGVtLm5ldFwvd3AtY29udGVudFwvdXBsb2Fkc1wvMjAxOVwvMDlcL3Nla2lsXzItMS5qcGciLCJ0aXRsZSI6InNla2lsXzIiLCJjYXB0aW9uIjoiXHUwMTVlZWtpbCAyLiBCb25jdWsgYm95dXR1bmRha2kgZGVcdTAxMWZpXHUwMTVmaW1pbiB2ZXJpbGVuIHNwZXNpZmlrIGVuZXJqaSB2ZSBoYXNzYXMgXHUwMGY2XHUwMTFmXHUwMGZjdG1lIHNvbnJhc1x1MDEzMSBzb24gcGFydGlrXHUwMGZjbCBib3l1dHVuYSBldGtpc2kiLCJhbHQiOiIiLCJkZXNjcmlwdGlvbiI6IiJ9,eyJ1cmwiOiJodHRwczpcL1wvd3d3LnR1cmtjaGVtLm5ldFwvd3AtY29udGVudFwvdXBsb2Fkc1wvMjAxOVwvMDlcL3Nla2lsXzMuanBnIiwidGl0bGUiOiJzZWtpbF8zIiwiY2FwdGlvbiI6Ilx1MDE1ZWVraWwgMy4gQm9uY3VrIGJveXV0dW5kYWtpIGRlXHUwMTFmaVx1MDE1ZmltaW4gXHUwMGZjclx1MDBmY24ga2FsaXRlc2luZSBldGtpc2kiLCJhbHQiOiIiLCJkZXNjcmlwdGlvbiI6IiJ9"] Difference Between Deagglomeration and True Grinding Effect Today pre-mixes are prepared using high speed dissolvers or relatively simple rotor-stator systems. However, with these systems true grinding – meaning actual reduction in particle size – cannot be achieved. These systems only distribute agglomerates (clumps) (Figure 4), helping real grinding to take place. This way, relatively weak forces such as van der Waals, electrostatic, and magnetic forces between molecules are overcome. However, without the use of beads, true grinding cannot occur and strong intramolecular bonds cannot be broken to achieve real size reduction. (Figure 4)

Figure 4. True grinding

 

Higher Efficiency Throughout the Entire Process

This is where our MacroMedia™ pre-grinding solution comes in and revolutionizes the wet grinding process. With Macromedia™ we increase final product quality, accelerate the process and reduce costs. As you can see in Figures 5 and 6, MacroMedia™ is a machine that combines bead grinding with existing rotor-stator systems and features an integrated pump. By fitting all this into a very compact machine, we can significantly reduce the footprint required for this process at the facility. [gallery size="medium" columns="2" ids="eyJ1cmwiOiJodHRwczpcL1wvd3d3LnR1cmtjaGVtLm5ldFwvd3AtY29udGVudFwvdXBsb2Fkc1wvMjAxOVwvMDlcL21hY3JvX21lZGlhLmpwZyIsInRpdGxlIjoibWFjcm9fbWVkaWEiLCJjYXB0aW9uIjoiXHUwMTVlZWtpbCA1LiBNYWNyb01lZGlhJiN4MjEyMjsgeWFwXHUwMTMxc1x1MDEzMSIsImFsdCI6IiIsImRlc2NyaXB0aW9uIjoiIn0=,eyJ1cmwiOiJodHRwczpcL1wvd3d3LnR1cmtjaGVtLm5ldFwvd3AtY29udGVudFwvdXBsb2Fkc1wvMjAxOVwvMDlcL21hY3JvX21lZGlhXzIuanBnIiwidGl0bGUiOiJtYWNyb19tZWRpYV8yIiwiY2FwdGlvbiI6Ilx1MDE1ZWVraWwgNi4gTWFjcm9NZWRpYSYjeDIxMjI7IHRla25payB2ZXJpbGVyIiwiYWx0IjoiIiwiZGVzY3JpcHRpb24iOiIifQ=="] MacroMedia™ is specially patented and features a unique design where the rotor system also performs bead separation. This entire structure is surrounded by a pin system and consists of two intertwined process chambers and an integrated pump. This makes MacroMedia™ the only bead-based pre-dispersing machine in the world. Moreover, it achieves all this in a 6-liter process chamber with high throughputs of 10,000 l/hour to 15,000 l/hour. This eliminates the need for a high speed dissolver. (Table 1)

Table 1. Alternative production methods

Figure 7. Modular platform solution (1. Dosing liquids and powders to mixing tank, 2. Circulation between mixing tank and MacroMedia™, 3. Transfer from mixing tank to recirculation tank with MacroMedia™, 4. Circulation between recirculation tank with MicroMedia+™, 5. Transfer from recirculation tank to let-down tank with MicroMedia+™, 6. Addition of liquid components and transfer to next production process)

Pre-Grinding and Fine Grinding in a Single Facility with Modular Platform Solution

Our pre-grinding machine MacroMedia™ and our bead mills MicroMedia+™ or Cenomic™ for fine grinding, contained in our compact production module, deliver the most efficient wet grinding process in a small footprint. The pre-designed module minimizes assembly and commissioning time. This solution offers a cost-effective production opportunity for demanding wet grinding tasks. Examples from Our Industrial Applications 1. Packaging Inks: Productivity Increase This study demonstrates how integrating MacroMedia™ into the system significantly increases productivity.

Previous Process:

• Particle size after pre-grinding: 300-500 µm, • High-energy bead mill MicroMedia™ for fine grinding using 0.8 mm beads and 0.35 mm filter size, • Energy consumption for production: 350 kWh/t for accuracy below 5 µm.

Benefits of Production with MacroMedia™:

• Pre-grinding with MacroMedia™ using 3.0 mm bead size achieving below 100 µm, • Fine grinding with MicroMedia™ using 0.3 mm bead size, • Energy consumption reduced to 200 kWh/t with no change in quality level and facility capacity increased by 75%.

2. Pigment Concentrates: Increased Process Reliability

Another study demonstrates increased process reliability. Production with MacroMedia™ is much more flexible and stable. Previous Process: • Batch process production with mobile tanks, • Raw material preparation with conventional mixing systems, • Forced immediate entry into process to prevent sedimentation, resulting in loss of production flexibility.

Benefits of Production with MacroMedia™:

• Preparation of stable suspension, • Minimized sedimentation creating flexible production process, • Prevention of bead mill clogging, • Increased process reliability and efficiency of the facility. Aybars Kaya Regional Sales Director GD – Turkey